Concealed three port flushometer system

ABSTRACT

A flushometer system having an integrated control stop and three ports. The piston or flush control device is accessible through an actuation opening. The flushometer system may be utilized in a behind-the-wall installation with a face plate exterior for user interaction. The interior of the flushometer may be accessed through the actuation opening behind the face plate.

TECHNICAL FIELD

The present disclosure relates generally to systems for flushometers,more specifically for flushometers disposed behind a wall (in-wall) withan exposed actuation mechanism.

BACKGROUND

Flushometers are a ubiquitous presence in most commercial restrooms, aswell as in many homes. Flushometers typically utilize a familiar valvebody having an inlet, an outlet, a handle opening, and a removable capfor accessing the valve. Thus, most flushometer valve bodies rely upon afour-port arrangement. Further, most such flushometers utilize a controlstop associated with the valve body and positioned immediately upstreamof the water supply, allowing the valve to be isolated from the watersupply line by closing the control stop.

In-wall flushometers are known, but present a problem of access formaintenance and replacement. The four-port design requires a much largerfreedom of access and working space than is typically available forin-wall or behind-wall installations. Further, the use of a control stoprequires both a larger volume of area that must be accessed and furtherincreases the mass of material that must be placed behind or in thewall.

In addition, flushometers in the art typically were designed for anenvironment where water conservation was not a consideration. Thus, atypical flushometer is not concerned with performance in a low flushvolume environment, resulting in poor or undesirable performance oftypical flush valves when put into service in a low flush volumeenvironment. However, lower flush volumes exacerbate certain aspects ofa flushometer's performance, such as a tendency to exhibit a harmfulshock to the system upon opening and upon closing due to the abruptchange in flow. Further, the design of flushometer valves is such thatif the valve fails, i.e. remains open, the valve is at its highest flowrate. This results in both a large amount of wasted water as well as anincreased potential for an overflow from the associated toilet or urinalwhich may not be able to drain such a high flow rate when providedcontinuously.

Thus, there is a need for flushometers that provide for improved accessin behind-the-wall or concealed applications.

SUMMARY

Embodiments described herein relate generally to a flushometer system.The flushometer system has a valve body having an inlet, an outlet, andan actuation opening. A valve seat assembly is disposed in the valvebody between the inlet and the outlet. A sleeve is adjustably engageablewith the valve body, the sleeve movable relative to the valve body to beengaged and disengaged from the valve seat assembly. A piston valveassembly is disposed within the sleeve and configured to engage thevalve seat assembly to close the flushometer system. An actuation moduleis engaged with the sleeve and has a relief valve, the actuation modulesecured at the actuation opening with a locking mechanism. A flowcontrol extends from the piston assembly, the flow control comprising asnubber portion, a flush profile portion, and a plug portion.

Another embodiment relates to a concealed flushometer system. The systemcomprises a valve body having an inlet, an outlet, and an actuationopening. A valve seat assembly is disposed in the valve body between theinlet and the outlet. A sleeve is adjustably engageable with the valvebody, the sleeve movable relative to the valve body to be engaged anddisengaged from the valve seat assembly. A piston valve assembly isdisposable within the sleeve and configured to engage the valve seatassembly to close the flushometer system. An actuation module isengageable with the sleeve and having a relief valve, the actuationmodule secured at the actuation opening with a locking mechanism. A faceplate assembly has a face plate push button and a mounting ring, themounting ring configured to engage a structure behind which the valvebody is positioned. The mounting ring further includes mounting ringopening through which a face plate is engagable with the relief valve;

Yet another embodiment relates to a flushometer system comprising avalve body having an inlet, an outlet, and an actuation opening. A valveseat assembly is disposed in the valve body between the inlet and theoutlet. A sleeve is adjustably engageable with the valve body, thesleeve movable relative to the valve body to be engaged and disengagedfrom the valve seat assembly. An actuation module is engageable with thesleeve, the actuation module secured at the actuation opening with alocking mechanism. A flow control is disposable within the sleeve andconfigured to engage the valve seat assembly to close the flushometersystem, the flow control in communication and controlled by theactuation module. The locking mechanism is engageable with a shoulderdisposed adjacent the actuation opening, the locking mechanism at leastpartially captured between the shoulder of the valve body and theactuation module when the sleeve is spaced apart from the valve seatassembly and the locking mechanism being disengaged from the actuationmodule when the sleeve is engaged with the valve seat assembly.

It should be appreciated that all combinations of the foregoing conceptsand additional concepts discussed in greater detail below (provided suchconcepts are not mutually inconsistent) are contemplated as being partof the subject matter disclosed herein. In particular, all combinationsof claimed subject matter appearing at the end of this disclosure arecontemplated as being part of the subject matter disclosed herein.

BRIEF DESCRIPTION OF DRAWINGS

The foregoing and other features of the present disclosure will becomemore fully apparent from the following description and appended claims,taken in conjunction with the accompanying drawings. Understanding thatthese drawings depict only several implementations in accordance withthe disclosure and are therefore, not to be considered limiting of itsscope, the disclosure will be described with additional specificity anddetail through use of the accompanying drawings.

FIG. 1 is an exploded perspective view of one embodiment of aflushometer system.

FIG. 2A is a view of one embodiment a flushometer from the inlet with asleeve serving as a stop (control stop) in the open position; FIG. 2Bshows the control stop of FIG. 2A in the closed position, i.e. with thesleeve contacting a main valve seat.

FIG. 3A illustrates one embodiment of a flushometer with a main valveseat assembly positioned in the valve body, as viewed in perspectivethrough the actuation opening from the side; FIG. 3B illustrates oneembodiment of a flushometer with a main valve seat assembly positionedin the valve body, as viewed in perspective through the actuationopening from the outlet;

FIG. 4A illustrates a side view of one embodiment of a main valve seatassembly; FIG. 4B illustrates a perspective view of one embodiment of amain valve seat assembly.

FIG. 5A illustrates one embodiment of an actuation module, pistonassembly, and sleeve; FIG. 5B illustrates a partial cross-section of oneembodiment of a flushometer highlighting the actuation module 310 andpiston 220 positioning when assembled; FIG. 5C is an isolatedcross-section of the actuation module 310; FIG. 5D illustrates a partialcross-section of one embodiment of a flushometer highlighting theactuation module 310 and piston 220 positioning when assembled for adevice with an automatic actuation mechanism; FIG. 5E is an isolatedcross-section of the automatic actuation mechanism of FIG. 5D

FIG. 6A illustrates a side view of one embodiment of a piston assembly,FIG. 6B illustrates a perspective view of one embodiment of a pistonassembly; FIG. 6C illustrates a view from the flow control end of anembodiment of a piston assembly.

FIG. 7A illustrates one embodiment of a valve body in perspective; FIG.7B is a back perspective view of one embodiment of a valve body;

FIG. 7C is a side view of one embodiment of a valve body.

FIG. 8A is a perspective view of one embodiment of an automaticactuation module secured with a locking mechanism to an actuationopening of a valve body; FIG. 8B is a perspective view of an automaticactuation module; FIG. 8C is a perspective view of a manual actuationmodule.

FIG. 9 is a perspective view of one embodiment of a locking mechanismand the actuation opening of a valve body.

FIG. 10A shows a perspective, partial view of one embodiment of aflushometer system with a mounting plate and actuation mechanism securedin place and the face plate open; FIG. 10B is a front view of aflushometer system mounted behind a wall with the face plate exposed andopen for accessing the actuation module.

FIG. 11 illustrates a close-up partial view of a face plate exteriormounted to a mounting plate.

FIG. 12 illustrates the application of a tool to the actuation modulebonnet to adjust the sleeve.

FIG. 13 illustrates a partial cut-away view of one embodiment of a flushsystem installed behind a wall for a urinal.

FIG. 14 illustrates one embodiment of a flush system with a tool forengaging the actuation module bonnet.

FIG. 15 illustrates an embodiment of a rolling diaphragm assembly with aplug for a slow start feature.

Reference is made to the accompanying drawings throughout the followingdetailed description. In the drawings, similar symbols typicallyidentify similar components, unless context dictates otherwise. Theillustrative implementations described in the detailed description,drawings, and claims are not meant to be limiting. Other implementationsmay be utilized, and other changes may be made, without departing fromthe spirit or scope of the subject matter presented here. It will bereadily understood that the aspects of the present disclosure, asgenerally described herein, and illustrated in the figures, can bearranged, substituted, combined, and designed in a wide variety ofdifferent configurations, all of which are explicitly contemplated andmade part of this disclosure.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS

Embodiments described herein relate generally to a flushometer systemand methods for same.

In one embodiment, the flushometer system 10 includes a valve body 110.FIG. 1 generally illustrates the structure of one embodiment of aflushometer system 10. As seen in FIG. 1, the valve body 110 includes aninlet 80 and an outlet 90. The inlet 80 maybe be positioned at a top ofthe valve body 110 and the outlet 90 positioned at the bottom. Anactuation opening 105 may be positioned substantially perpendicular toan axis running through the inlet 80 and outlet 90. It should beappreciated the positioning of the inlet 80, outlet 90, and actuationopening 105 relative to space (i.e. which is up/down/etc.) can bechanged and the described relative orientations maintained as described.In the embodiments illustrated in the Figures, the inlet 80 and theoutlet 90 are parallel, essentially providing fluid at a top of thevalve and evacuating fluid at the bottom. The actuation opening 105 ispositioned perpendicular to the inlet 80 and outlet 90. However, inalternative embodiments the inlet 80 may be positioned on alternative“faces” of the valve, for example positioned for a side-entry,perpendicular to both the actuation opening 105 and the outlet 90.

Disposed between the inlet 80 and the outlet 90, as well as adjacent theactuation opening 105 is a valve chamber 112, in which a piston assembly210 and main valve seat 152 are positioned and which is defined by thespace between the piston assembly 210, the inlet and the outlet 90, andthrough which water flows during a flush. The valve chamber 112 is opento the inlet 80 through the inlet aperture 81 (which may be sealed bythe sleeve acting as a control stop through engagement of the main valveseat assembly 150 by the sleeve 170 as described below) and open to theoutlet 90 through the valve chamber outlet 91 (best seen in FIG. 5B)(controlled by the main valve seat assembly 150 as described below) andalso open to the actuation opening 105 (sealed by the actuation module310 and piston assembly 210 as described below). Thus, water flowsthrough the valve chamber 112 controlled or sealed at each opening bystructure as indicated below.

In one embodiment, best shown in FIGS. 2A and 2B, the inlet 80 includesan inlet aperture 81. The inlet aperture 81 may have a smaller area thanthe inlet 80. Further, the inlet aperture 81 may have a selected shape,such as a rectangle with curved corners. The inlet aperture 81 serves torestrict the flow of water into the valve chamber 112. In oneembodiment, the inlet aperture 81 allows water to flow to the pistonassembly 210 with a minimum number of turns in its flow path from theinlet 81. In addition, the inlet aperture 81 may interact with thesleeve 170 as described below.

The valve chamber 112 includes a valve seat receptacle 114. The valveseat receptacle 114 may comprise a threaded portion of the valve body110 within the valve chamber 112 or may include a physical structure toallow for a main valve seat assembly 150 to be retained, such as bysnap-fit, twist-and-lock, or the like. In one embodiment, the valve seatreceptacle 114 is adjacent the valve chamber outlet 91 (best illustratedin FIGS. 5B and 5D). Preferably, the valve seat receptacle 114 and mainvalve seat assembly 150 are sized to position a main valve seat 152 ofthe main valve seat assembly 150 adjacent the inlet aperture 81, such asbest seen in FIG. 5B (interior view) and FIG. 3A (exterior view).

FIGS. 4A and 4B show one embodiment of a main valve seat assembly 150outside of the valve body 110. The main valve seat assembly 150 includesa retention mechanism 151, a main valve seat 152, a main valve seatinlet 157 and one or more main valve outlets 160. In one embodiment, asshown in FIG. 4A, a main valve seat assembly control stop seal 154 isprovided. The control stop seal 154 engages the valve body as shown inFIG. 2A. The control stop seal 154 is engageable with the sleeve 170 tofunction as a control stop, sealing water from entering the valvechamber 112. In the illustrated embodiment, the main valve seat assembly150 is substantially circular in cross-section, forming a generallycylindrical shape with an outer wall and both faces of the cylinderbeing openings. The main valve seat 152 circumscribes the main valveseat inlet 157, which opens into the interior of the main valve seatassembly 150, which is essentially defined by a housing or structureabout the periphery. The main valve seat assembly 150 of the FIG. 4Aincludes a threaded portion as the valve seat receptacle 114 whichextends into a machined and threaded portion of the valve chamber 112opposite of the actuation opening 105. Thus, as seen in FIG. 3A, themain valve seat assembly 150 may be threaded into the valve seatreceptacle 114 of the valve body. The one or more main valve outlets 160are voids, windows, openings, or the like, in the housing of the mainvalve seat assembly 150. The one or more main valve outlets 160 providefor communication from within the main valve seat assembly 150 and theoutlet 90. Thus, water can flow through the main valve seat inlet 157through the interior of the main valve seat assembly 150 and through theone or more main valve outlets 160.

When the main valve seat assembly 150 is positioned in the valve body110, any fluid that would flow through the flushometer 10, must flowthrough the inlet aperture 81, over the main valve seat 152, through themain valve seat inlet 157 and then out the one or more main valveoutlets 160. The one or more main valve outlets 160 open to the outlet90 through the valve chamber outlet 91.

In some embodiments, a sleeve receptacle 116 of the valve body 110 isconfigured to receive a sleeve 170. The sleeve 170 may be a cylindrical(or similar) structure defining a hollow interior and open at both facesof the cylindrical shape. The sleeve receptacle 116 may comprise athreaded portion of the valve body 110 within the valve chamber 112 ormay include a physical structure to allow for the sleeve 170 to beretained, such as by snap-fit, twist-and-lock, or the like. The sleeve170 interacts with the piston assembly 210 and the actuation module 310as further described below to define the relief chamber 201.

In addition, the sleeve 170 also provides a shut-off mechanism or“control stop” valve. Thus, the control stop is integrated with thevalve itself rather than positioned as a separate structure on the waterline as is typical. As best seen in FIG. 5, the sleeve 170 has a sleevevalve seat end which is positioned nearest to the main valve seat 152and the inlet aperture 81 and an opposite bonnet end that engages withthe bonnet 320 of the actuation module 310 as described below. As bestshown in FIGS. 2A and 2B, the sleeve 170 may be adjustable relative tothe control stop seal 154 of the main valve seat assembly 150 and/or theinlet aperture 81. The sleeve 170 may, thus, be repositioned to adjustthe relative position of the sleeve 170 and the inlet aperture 81 andmain valve seat 152. The sleeve 170 can extend towards the main valveseat 152, covering a portion or the entire inlet aperture 81. When thesleeve 170 is advanced towards the main valve seat 152 to contact themain valve seat 152, the main valve inlet 157 is effectively sealed offfrom the inlet aperture 81, thus closing the flushometer 10 from supplywater. FIGS. 2A and 2B show the sleeve 170 in various positions as seenthrough the inlet aperture 81.

In one embodiment, the sleeve 170 in conjunction with the control stopseal 154, is an adjustable throttling mechanism. That is, the spacebetween the sleeve 170 and the control stop seal 154 can be adjusted asdesired to restrict flow, allowing for adjustment to the GPM of waterpassing through the inlet 80 and through the main valve assembly outlets160.

In one embodiment, engaging with the main valve seat assembly 150 is apiston assembly 210, shown in FIG. 5 engaging the sleeve 170 and shownseparately in FIGS. 6A-6C. The piston assembly 210 is positioned withinthe valve body 110 through the actuation opening 105. The pistonassembly 210 is disposable within the interior of the sleeve 170 andengageable with the valve seat assembly 150. One embodiment of thepiston assembly 210 includes a piston 220 and a flow control 270.

As seen in FIGS. 5A, 5B, and 5D, the piston 220, of the piston assembly210, is disposable within the sleeve 170. The piston 220 has a hollowbody with a largest diameter at a top lip seal portion 230 (activationside), a relief portion 240 having a reduced diameter and positioned inthe middle of the piston assembly 210, and a main valve seal portion 250which, in the illustrated embodiment, both engages the flow control 270and is engageable with the main valve seat assembly 150 to close theflushometer 10.

With regard to FIG. 6A-6C, the top lip seal portion 230 of the piston220 provides a seal 231 between the piston 220 and the sleeve 170. Thisseal 231 separates the relief chamber 201, i.e., the environment definedby the interior of the piston and between the piston 220 and theactuation module 310 from the valve chamber 112, i.e. the environmentwithin the sleeve 170 (between the sleeve 170 and the piston 220) whichextends through to the main valve seat assembly and, to be incommunication with the inlet 80 and, when the valve is open, the outlet90. As would be understood from similar function in prior piston valves,the lip seal 231 also serves to maintain the position of the pistonassembly 210 relative to the sleeve 170.

With continued reference to FIGS. 6A-6C, the relief portion 240 of thepiston 220 includes one or more by-pass openings (not shown). Theby-pass openings (not shown) allow fluid to pass from the environmentoutside of the piston 220 (within the relief chamber 201) to within thepiston 220. The by-pass openings (not shown) may utilize technology asknown in the art for piston valves, such as including a filter 242. Thefilter 242 may be positioned in a corresponding groove 243, such as acircumferential groove 243 (best shown in FIG. 5b ). The by-passopenings may be a group of slots or holes within the groove 243 wherethe filter 242 is positioned within the groove 243 and functions toprevent the clogging of the by-pass openings, such as by debris in waterfrom the inlet 80. Preferably there are at least two by-pass openingsequally spaced about the relief portion 240.

The main valve seal portion 250 of the piston 220 includes a sealsurface 251 for engaging and sealing the valve against the main valveseat 152. The seal surface 251 seats upon the valve seat 152 when theflushometer 10 is closed. The flow control 270, attaches to the piston220, such as at the main valve seal portion 250.

The flow control 270, of the piston assembly 210 is configured tocontrol and define the flush profile. In the embodiments shown, the flowcontrol 270 includes a “dumbbell” shape, with a larger (relative to theflush profile portion 280) circumference snubber portion 275, a smallercircumference flush profile portion 280 and a larger (relative to theflush profile portion 280) plug portion 290. The flow control 270 may beprofiled, such as with rounded edges at the downstream portion toprovide for water flow efficiency.

The snubber portion 275 is sized so as to have a smaller outer diameterthan the main valve seal portion 250 and smaller than the inner diameterof the main valve seat 152. Thus, the snubber portion 275 is able to bedisposed within the main valve seat assembly 150, such as when the mainvalve seal 251 is engaged with the main valve seat 152. The height ofthe snubber portion 275, that is the distance it extends from the mainvalve seal portion 250 before transitioning to the flush profile portion280, may be selected to control the behavior of the flushometer 10 atclosing. For example, the presence of the snubber portion 275 at the endof a flush cycle reduces the volume of water initially passed throughthe flushometer 10 and also slows the seating of the main valve seal 251on the main valve seat 152 as the snubber portion 275 enters the mainvalve seat assembly 150. This lessens the impact of the flush cycle onthe system by more gradually presenting the water flow through the valverather than immediately moving to a maximum flow rate. Further, thesnubber portion 275 may be provided with hydraulic features 276 about atleast a portion of its periphery, such as refill flow grooves. Suchhydraulic features 276 may be used to control the performance just priorto and at the moment of valve closing.

The outer diameter of the plug portion 290 is preferable smaller thanthe outer diameter of the snubber 275, so as to avoid the valve runningat “full open” in the event the valve fails to close. Thus, if the flowcontrol 270 becomes detached, the device will “fail” with the snubberengaging the main valve seat 152. It will be appreciated this willresult in substantially lower volume of water per minute passing throughthe valve than if the valve failed into a fully open status.

The flush profile portion 280 extends from the snubber portion 275. Theouter diameter of the flush profile portion 280 is less than that of thesnubber portion 275, for example having less than ¾, ½ or ¼ diameter ofthe snubber portion 275 and/or the plug portion 290. In one embodimentthe difference in outer diameter may be partially or completelytransitioned by a taper. The size of the outer diameter of the flushprofile portion 280 corresponds with the flow rate of the flush or morespecifically the flow rate while the flush profile portion 280 ispositioned at the main valve seat and controlling fluid flow. Thedistance the flush profile portion 280 extends from the snubber portion275 controls the flush timing, or more specifically the flush timing forthe associated portion of the flush profile.

The plug portion 290 extends from the flush profile portion 280. Theouter diameter of the flush profile portion 280 is less than that of theplug portion 290. In one embodiment the difference in outer diameter maybe partially or completely transitioned by a taper. In one embodiment,the plug portion 290 includes contouring for a desired flush profile.The plug portion 290 imparts a “slow open” or “slow opening” to theflushometer system 10. The plug portion 290 hydraulically dampens themovement of the piston, essentially slowing down the opening of the mainvalve. In some embodiments the plug portion 290 provides for a reducedimpact on the infrastructure of the system due to the slower open.Further, the slow opening allows the purging of air from within thevalve at a lower GPM, thus allowing for a more efficient flush as highGPM is not used to move air.

The slow opening demonstrates a number of characteristics thatdistinguish from the “normal” opening for prior art valves. Slowopening-isolates the stroke variance of an actuation module 310, such asa relief valve 200. That is, the stroke or distance traveled by therelief valve stem 355 is not a controlling variable for the flush.Rather, the structure that enables a slow opening provides forinsensitivity to stroke variance, and more tolerance of the ventingmethod; (solenoid vs. manual) as the venting of relief chamber 201becomes less critical because of the slow opening plug portion 290 (i.e.vent rate of the mechanism and causes thereof unlike existing art).

The slow opening reduces the acceleration of GPM during the initialstage of flush cycle (˜1^(st) few milliseconds) this feature extendsthis to a much longer time (˜1 second) and through this feature cancontrol the acceleration of GPM at this time of the flush cycle. Theplug portion 290 has top surface that has a shape that controls the rateof change of the acceleration (rate of change) of GPM.

The O.D. of plug portion 290 and I.D. of main valve seat assembly 150define an annulus allowing water flow through the valve when the plugportion 290 is fully engaged with the main valve seat assembly 150.

The flow control portion 270 may include one or more contours on thesnubber portion 275, the flush control 280 or the plug portion 290,including at the transitions there between such as contour 291 in FIG.6A.

The plug portion 290 may include one or more contours or groovesdefining the outer perimeter. For example, a groove 292 in the plugportion 290 is configured to receive a plug portion seal (not show),which provides for reduction of “blow by” converging onto zero GPM byintroducing the seal into groove 292 as to further reduce annulus andflow there through such as a full open condition (max GPM) of the valve.Thus, in one embodiment when the flushometer 10 is open and the pistonassembly 210 is fully retracted from the main valve seat 152, the plugportion 290 may be positioned to restrict the flow of water through theflushometer 10. In the event that the valve fails or a user holds theactivation mechanism and the flushometer 10 remains in an open position,the plug portion 290 reduces the flow rate of water dispensed from theflushometer 10, reducing wasted water and lessening the likelihood of anoverflow from the urinal or toilet.

The plug portion 290 is positioned, when the valve is closed, within themain valve seat assembly. During a flush cycle, the plug portion 290moves relative to the main valve seat 152. When the main valve seat seal251 disengages from the main valve seat 152, water is able to flow overthe main valve seat 152. As the plug portion 290 is still within themain valve seat assembly 150, the water must flow over and around theperimeter of the plug portion 290. As the plug portion 290 is present inthe path the water would take through the main valve seat assembly 150,the volume of water per time unite (such as GPM) able to pass throughthe main valve seat assembly is reduced.

In one embodiment, the main valve seat retention mechanism 151 extendsfrom the one or more main valve outlets 160, opposite the main valveseat 152. The valve seat receptacle 114 may be configured to receive thevalve seat retention mechanism 151. In one embodiment, when the pistonassembly 210 is in a closed position, the plug portion 290 of the flowcontrol 270 is at least partially positioned within the retentionmechanism 151 and the valve seat receptacle 114 of the valve body 110.In this resting or closed position, the flow control portion 270 ispositioned adjacent the one or more main valve outlets 160, for examplecircumscribed by the one or more main valve outlets 160.

It should be appreciated the relative heights of the various portions ofthe flow control 270 can be adjusted and may, as a result, alter thepositions relative to the parts of the main valve seat assembly 150during the closed state.

Turning back to FIG. 5A, the piston assembly 210 and the sleeve 170 areengageable with a actuation module 310, with the actuation assembly andsleeve 170 defining a relief chamber 201 where the piston 220 isdisposed. The actuation module 310 is actuated by an actuation mechanism350.

The actuation module 310, as shown in FIG. 1, is located distal to themain valve, i.e. on the opposite end of the piston assembly 210 as themain valve seat assembly 150 is engaged. The actuation opening 105includes an increased diameter from the sleeve receptacle 116 portion ofthe valve chamber 112. The increased diameter of the valve body 110 fromthe sleeve receptacle 116 to the actuation opening 105 forms anactivation opening shoulder 106 (in one embodiment, substantiallyparallel with the valve seat and substantially perpendicular to alongitudinal axis of the sleeve 170). Thus, as best shown in FIG. 7A-B,a venting chamber 115 (best shown in FIG. 1 and FIG. 5B) exists aboutthe sleeve 170 at a sleeve activation end 174 (FIG. 5A), between thesleeve 170 and the valve body 110, further defined by the activationopening shoulder 106 and the actuation module 310 (described furtherbelow). This venting chamber 115 is in fluid communication with theoutlet 90 through a venting journal 108 in the valve body 110. Theventing journal 108 provides a passage from the venting chamber 115 tothe outlet 90. FIG. 7A and FIG. 7B provide an illustration of theventing journal 108 without other components in installed.

In one embodiment, the sleeve 170 includes a plurality of splines 178spaced about the external perimeter of an upper portion (adjacent theactivation end) of the sleeve 170. FIG. 5A illustrates the plurality ofsplines 178 prior to engagement with a corresponding plurality ofsprockets 324 in a bonnet 320 of the actuation module 310.Alternatively, the sleeve 170 and actuation module 310 may engage bytongue and groove, turn-and-lock, press-fit, or the like, so as to allowthe actuation module 310 to be removed as further described below.Preferably, the actuation module 310 is coupled with the sleeve 170 suchthat rotation of the actuation module 310 rotates the sleeve 170. Forexample, rotation of the actuation module may cause the sleeve tointeract with the retention mechanism to move the sleeve relative to themain valve seat assembly 150, closing the valve through action of thesleeve as a control stop.

As shown in FIGS. 5A-5E, an actuation module 310 includes a bonnet 320with an activation module passage 312 and a sleeve cap 340. A reliefvalve stem 355 extends from a top of the bonnet 320 through theactivation module passage 312 and, in one embodiment, through the sleevecap 340. The relief valve stem 355 may include an upper stem seal 356and a lower stem seal 357. The lower stem seal 357 may be retainedbetween a lower stem cap 359, where the lower stem cap 359 has a largerouter diameter than that of the activation module passage 312. As seenin FIG. 5B, the lower stem cap 359 may aid to retain the stem within thepassage 312 against a biasing mechanism 368 (also shown in FIG. 10A). Atleast one vent opening 314 in the activation module passage 312 abovethe sleeve cap 340 places the activation module passage 312 in fluidcommunication with an activation module exhaust chamber 370 definedbetween the bonnet 320 and the sleeve cap 340 and extending about theexterior of the sleeve 170 between the sleeve 170 and valve body 110 incommunication with the venting journal 108. A flow portion 354 of therelief valve stem 355 allows for passage of water between the reliefvalve stem 355 in the activation module passage 312. The flow portion354 does not fill the entire volume of the passage 312, for examplebecause it has a (+) shaped cross section or the like rather than acircular or because the outer diameter of the flow portion 354 is lessthan half that of the inner diameter of the passage 312. The reliefvalve stem 355 is slidable relative to the activation module passage312, allowing the lower stem seal 357 to be unseated and placing therelief chamber 201 in fluid communication with the activation modulepassage 312 and ultimately through the activation module passage 312 tothe exhaust chamber 370 and through the venting journal 108 to theoutlet, and, thus, the venting the relief chamber 201 to the outlet 90.The upper stem seal 356 is positioned such that it seals an upperportion of the activation module passage 312 above the vent opening 314.The relief valve stem 355 may include a head portion that acts as acontrol stop to limit the movement of the stem 355, such movement beinglimited such that the upper stem seal 356 does not enter the ventopening 314.

As best shown in FIG. 10a , the actuation module 310 may include abiasing mechanism 368 such as a spring. The spring 368 may engageagainst a relief valve stem head 356, which is at an activation end ofthe relief valve stem 355 and includes a larger circumference portionagainst which the spring is retained between the relief valve stem head356 and the bonnet 320.

With reference to 10A and 10B, an adjustment mechanism 365, such as anadjustment screw, nut, or the like, may be provided with the reliefvalve stem 355. The adjustment screw adjusts the relative position ofthe relief valve stem 355 and the face plate 450.

As seen in FIGS. 8A-8C, the actuation mechanism 350 may be an automaticactuation mechanism 360 or a manual actuation mechanism 350. A manualactuation mechanism 350 may include a manual activation face plate 450,such as shown in FIG. 10A. An automatic actuation mechanism 360 may be asolenoid or the like, such as shown in FIG. 8A. The operation of thedevice using an automatic actuation mechanism 360 is generally the sameas described below for a relief valve stem 355, except venting isaccomplished without the mechanical relief valve stem 355. It should beappreciated that the automatic actuation mechanism 360 may be actuatedby a sensor-controlled system “automatically”, i.e., without user input,or by user actuation or by both.

It should also be appreciated that the actuation mechanism can othertypes of venting known in the art, including a hydraulic valve control.The hydraulic valve control may be as known in the art and the actuatorfor the hydraulic valve control may be mechanically separate from thevalve 110 but in hydraulic communication.

As best shown in FIGS. 8B and 8C, the bonnet 320 may include one or morebosses 321 or protrusions for engaging with a removal tool 490(embodiments shown in FIGS. 12 and 14) to adjust the position of thebonnet 320, such as to thread the sleeve 170 to contact the main valveseat 152. In one embodiment, a removal tool 490 may be used for engagingthe bonnet 320 of the actuation module 310. The tool 490 is configuredto have an engagement surface that mirrors the contours of the bonnet320 to allow a user to rotate the bonnet by action of the tool. The tool490 is also sized so as to fit within the face plate assembly opening.FIG. 12 illustrates one example of a removal tool in use. The one ormore bosses 321 may also be threaded to allow for removal of theactuation module 310 by a tool (not shown).

The bonnet 320 may also include one or more air passages that may act asa vacuum breaker, such as check valves. The air passages provideadditional air to the activation module exhaust chamber. The airpassages may be, for example, included in the one or more bosses 321. Inone embodiment, shown in FIG. 8B, as discussed above, at least one boss321 is a tool receiving boss 321A, which includes a thicker wall and maybe threaded to engage a pulling tool (not shown). Preferably, there aretwo tool receiving bosses 321A positioned opposite each other on thebonnet 320 to allow for engagement by a tool to impart a rotation and,for threaded boss embodiments, pulling action to the bonnet for removal.There may also be one or more vacuum breaker bosses 321B, which providea vacuum breaker valve between the interior of the actuation module 310,including the exhaust chamber 370 and the external environment that isexposed beyond the bonnet (through the face plate assembly 410.

With reference to FIG. 8A and FIG. 9, a locking mechanism 390 is furtherprovided in one embodiment. The locking mechanism 390 removably retainsthe actuation module 310 within the actuation opening. In oneembodiment, such as shown in FIG. 9, the locking mechanism 390 is aretaining ring, such as a “c” locking retaining ring where the ring hasan opening or throat allowing the ring to expand or compresscircumference slightly to lock or release, respectively. The retainingring has an upper retaining ring ridge 391 and a lower retaining ringridge 393 and a retaining ring groove 392 there between. The valve body110 at the actuation opening 105 includes a shoulder 117 for engagingthe groove 392. The shoulder 117 may be defined, such as shown in FIG.7A, by a groove 118 in the valve body 110 at the actuation opening 105,such that the shoulder 117 has substantially the same inner diameter asthe actuation opening 105 and the groove 118 has a larger innerdiameter. Turning back to FIG. 8A and FIG. 9, the bonnet 320 includes aperiphery having a diameter sized to allow the locking mechanism 390 tobe disposed about it. The actuation module 310, piston assembly 210 andsleeve 170 may be threaded into the valve body 110 a distance to allowthe locking mechanism 390 to be inserted or removed. In a preferredembodiment, the locking mechanism 390 is only removable (or insertable)when the sleeve 170 is engaged with the main valve seat 152, thusoperating as a control stop and closing the valve, ensuring theactuation module 310 and piston assembly 210 can only be removed whenthe sleeve 170 is engaged as a control stop, i.e. the water from theinlet is shut off. When sleeve 170 is not positioned against the mainvalve seat 152, the actuation module 310, and sleeve 170 are separatedfrom the main valve seat 152 and the bonnet 320 engages the lockingmechanism 390 while the locking mechanism 390 also engages the valvebody 110. The locking mechanism 390 retains the actuation module 310from being removed while the locking mechanism 390 is in place relativeto the valve body 110. It should be appreciated that the lockingmechanism 390 may utilize a groove on the valve body that engages aprotrusion of the locking mechanism or vice versa.

In an alternative embodiment, show in FIG. 15, the piston assembly 210is replaced by a diaphragm assembly. The diaphragm assembly wouldutilize a diaphragm 510 with one or more bypasses (not show), toseparate the relief valve chamber 201 from the valve chamber 112. Thediaphragm 510 maybe integral with the sleeve, or alternatively, capturedbetween the sleeve and piston assembly 210. The piston 220 and flowcontrol 270 would extend from the diaphragm 510 (which may be positionedadjacent and about the periphery of the piston 220, as shown in FIG. 15)towards the main valve seat assembly 150 as is described above for thepiston valve. Further, alternative mechanisms such as a rollingdiaphragm may be used. For use with a diaphragm assembly or adiaphragm-like assembly (as opposed to a solenoid or piston describedabove), the diaphragm 510 could be as known in the art with thediaphragm assembly. FIG. 15 illustrates an embodiment with a rollingdiaphragm 510 held in place by one or more retaining nuts 520.

As shown in FIG. 13, with components best statically illustrated inFIGS. 10A-10B and FIG. 14, the manual actuation module 350 is actuatedby a face plate assembly 410. The face plate assembly 410 may include aface plate 450 and a mounting ring 420. The mounting ring 420 isremovably securable to the valve body 110. The face plate 450 is securedto the mounting ring 420. In one embodiment, the face plate 450 ispivotably mounted on the mounting ring 420 at a first end. The faceplate 450 includes an actuation surface 455 that is configured to engagethe actuation module 310 through a mounting ring opening 421.Specifically, the actuation surface 455 is engageable with the reliefvalve stem 355, such as the relief valve stem adjustment mechanism 365to slide the relief valve stem 355 against the biasing mechanism 368,such as a spring, to cause a relief valve stem lower seal to unsealopening the pathway for water to exhaust from the relief chamber. In oneembodiment, the actuation surface 455 is configured to interact with therelief valve stem 355 such that the movement of the face plate 450 as itpivots towards the valve body 110 is translated substantially intolinear movement, sliding the relief valve stem 355. This may beaccomplished by “rolling motion” to reduce wear.

In one embodiment, the face plate 450 is able to pivot away from themounting ring 420 and valve body 110 to allow access to the actuationmodule 310 through the mounting ring 420 (and any exterior face platecover 470). A face plate retainer 457 may be utilized to secure the faceplate 450 from such movement away from the mounting ring 420, forexample through the use of a pair of tabs. Thus, the face plate 450 isretained in a “down” position for engaging the relief valve stem 355.The face plate 450 may be pivoted away from the mounting ring 420 byreleasing the face plate retainer 457. The face plate assembly 410 mayfurther include an access mode retainer (not show), that retains theface plate in a position pivoted away (See FIG. 14) from the mountingring 420. When in such a position, as shown in FIG. 14, the face plate450 is retained so as to allow a user to access the bonnet 320 withoutneed to hold the face plate 450 up. For example, the access moderetainer (not shown) may be a biasing spring, or one or more interactingtabs that interact with the mounting ring 420 and are positioned at anopposite end of the face plate 450 from the face plate retainer 457.

As best seen in FIGS. 11 and 14, in one embodiment, the face plateassembly 410 includes the mounting ring 420 and an exterior face platecover 470. The face plate cover 470 may be retained to the mounting ring420, but otherwise serves to cover the mounting ring 420 and present anappealing aesthetic to the user. In one embodiment the face plate cover470 corresponds with a decorative tile, such as by having a similar sizeand shape, for example 4 inch square shape to match a standard 4 inchtile. The mounting ring 420 allows for, in one embodiment, a 5 degreerotational mismatch while still allowing the face plate cover 470 to bemounted squarely to the washroom wall trim.

The valve body 110 may include mounting brackets 106, such as shown bestin FIG. 7A.

In some embodiments, the system described functions as follows. A useractuates the system by pressing the face plate 450, which pivots toengage the relief valve stem 355. The relief valve stem 355 slideswithin the actuation mechanism passage and the relief valve stem lowerseal 357 unseats. This allows the hydraulic venting to begin. Theopening of the relief valve 200 exposes the relief chamber 201 to theexhaust chamber 370 to the low pressure (typically atmospheric) on theoutlet side of the flushometer 10. This creates an imbalance ofpressures on the piston assembly 210, as the inlet-side pressure withinthe valve chamber 112 is higher (typically 10-100 PSI). This results inthe piston 220 moving away from the main valve seat 152 as the valvechamber 112 enlarges and the relief chamber 201 shrinks. As the piston220 is unseated from the main valve seat 152, water is able to flow overthe main valve seat 152 from the inlet 80 and out through the one ormore main valve outlets 160 to the outlet 90. The movement of the piston220 also moves the attached flow control 270. For embodiments where theflow control includes a plug portion 290, the plug 290 restricts theflow of water (such as to about 5 gpm) until the plug portion 290 haswithdrawn from the main valve seat assembly 150 and water is free topass through the main valve seat assembly 150 without flowing over theplug 290. Thus, the initial phase of the flush cycle involves animmediate hydraulic venting but has a relatively low flow of watercomparative to the maximum possible flow rate from the inlet 80. As theflush cycle begins to conclude and the actuation mechanism 250, such asrelief valve 200, is closed, the bypasses allow for the pressure tobegin to equilibrate by refilling the relief chamber 201 (no longerexposed to the outlet 90) with water from the valve chamber 112. Thepiston 220 begins to travel back towards the main valve seat 152 toreseat. As the plug 290 re-enters the main valve seat assembly 150, theflow rate is affected. Further, as the closing event approaches for themain valve seat assembly 150, the snubber portion 275 of the flowcontrol 270 is disposed within the main valve inlet 157, the hydraulicinteraction with the snubber 275 slows the closing of the flushometer10.

The system, in some embodiments, allows for water delivery limits within10-100 PSI.

For embodiments utilizing a manual activation face plate, in oneapplication the manual activation requires no more than five pounds offorce to engage the activation module triggering a flush cycle to start.

In one embodiment, the valve provides a flush cycle having a flushprofile. The flush profile corresponds to the flow rate (typicallyexpressed as gallons per minute) at a given time and the time elapsedsince the flush cycle was initiated. The relative height of flow control270 controls the flush time while the relative outer circumference ofthe flow control 270 controls the flow rate. It should be appreciatedthe individual components of the flow control can have their heightand/or outer circumference varied to achieve a desired flush profile.

As used herein, the singular forms “a”, “an” and “the” include pluralreferents unless the context clearly dictates otherwise. Thus, forexample, the term “a member” is intended to mean a single member or acombination of members, “a material” is intended to mean one or morematerials, or a combination thereof.

As used herein, the terms “about” and “approximately” generally meanplus or minus 10% of the stated value. For example, about 0.5 wouldinclude 0.45 and 0.55, about 10 would include 9 to 11, about 1000 wouldinclude 900 to 1100.

It should be noted that the term “exemplary” as used herein to describevarious embodiments is intended to indicate that such embodiments arepossible examples, representations, and/or illustrations of possibleembodiments (and such term is not intended to connote that suchembodiments are necessarily extraordinary or superlative examples).

The terms “coupled,” “connected,” and the like as used herein mean thejoining of two members directly or indirectly to one another. Suchjoining may be stationary (e.g., permanent) or moveable (e.g., removableor releasable). Such joining may be achieved with the two members or thetwo members and any additional intermediate members being integrallyformed as a single unitary body with one another or with the two membersor the two members and any additional intermediate members beingattached to one another.

It is important to note that the construction and arrangement of thevarious exemplary embodiments are illustrative only. Although only a fewembodiments have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter described herein. Othersubstitutions, modifications, changes and omissions may also be made inthe design, operating conditions and arrangement of the variousexemplary embodiments without departing from the scope of the presentinvention.

While this specification contains many specific implementation details,these should not be construed as limitations on the scope of anyinventions or of what may be claimed, but rather as descriptions offeatures specific to particular implementations of particularinventions. Certain features described in this specification in thecontext of separate implementations can also be implemented incombination in a single implementation. Conversely, various featuresdescribed in the context of a single implementation can also beimplemented in multiple implementations separately or in any suitablesubcombination. Moreover, although features may be described above asacting in certain combinations and even initially claimed as such, oneor more features from a claimed combination can in some cases be excisedfrom the combination, and the claimed combination may be directed to asubcombination or variation of a subcombination.

What is claimed is:
 1. A flushometer system comprising: a valve bodyhaving an inlet, an outlet, and an actuation opening; a valve seatassembly disposed in the valve body between the inlet and the outlet; asleeve adjustably engageable with the valve body, the sleeve movablerelative to the valve body to be engaged and disengaged from the valveseat assembly; a piston valve assembly disposable within the sleeve andconfigured to engage the valve seat assembly to close the flushometersystem; an actuation module engageable with the sleeve and having arelief valve, the actuation module secured at the actuation opening witha locking mechanism; and a flow control extending from the pistonassembly, the flow control comprising a snubber portion, a flush profileportion, and a plug portion.
 2. The flushometer system of claim 1,wherein the activation module includes a plurality of bosses.
 3. Theflushometer system of claim 2, wherein the plurality of bosses includeat least one vacuum breaker boss and at least one tool receiving boss.4. The flushometer system of claim 1, wherein the valve body includes aninlet aperture adjacent the valve seat assembly and a venting journaladjacent to the sleeve and the outlet.
 5. The flushometer system ofclaim 1, wherein the main valve seat assembly comprises a main valveinlet and a plurality of main valve outlets.
 6. The flushometer systemof claim 5, wherein the main valve seat assembly is has a cylindricalshape with the main valve inlet on a first planar face and the pluralityof main valve outlets disposed about a curved surface.
 7. Theflushometer system of claim 5, wherein the flow control portion'ssnubber portion is positioned adjacent the piston assembly with theflush profile portion extending therefrom and the flow controlterminating with the plug portion extending from the flush profileportion.
 8. The flushometer system of claim 5 wherein an outer diameterof the snubber portion is greater than an inner diameter of the mainvalve inlet, an outer diameter of the plug portion is less than theinner diameter of the main valve inlet and an outer diameter of theflush profile portion is less than the outer diameter of the plugportion.
 9. A concealed flushometer system comprising: a valve bodyhaving an inlet, an outlet, and an actuation opening; a valve seatassembly disposed in the valve body between the inlet and the outlet; asleeve adjustably engageable with the valve body, the sleeve movablerelative to the valve body to be engaged and disengaged from the valveseat assembly; a piston valve assembly disposable within the sleeve andconfigured to engage the valve seat assembly to close the flushometersystem; an actuation module engageable with the sleeve and having arelief valve, the actuation module secured at the actuation opening witha locking mechanism; a face plate assembly having a face plate pushbutton and a mounting ring, the mounting ring configured to engage astructure behind which the valve body is positioned, the mounting ringfurther includes mounting ring opening through which a face plate isengageable with the relief valve;
 10. The concealed flushometer systemof claim 9, wherein the mounting ring opening has an inner diameterlarger than the outer diameter of the actuation opening of the valvebody.
 11. The concealed flushometer system of claim 9, wherein the faceplate includes a face plate actuation surface for engaging the valvestem.
 12. The concealed flushometer system of claim 9, wherein therelief valve stem includes a relief valve stem adjustment mechanism thatis extendable relative to the valve body.
 13. The concealed flushometersystem of claim 9, wherein the face plate is pivotally mounted withregard to the mounting ring such that the face plate pivots about ahinge towards the valve body to engage the valve stem and is pivotablyaway from the valve body to expose the actuation module through themounting ring opening.
 14. A flushometer system comprising: a valve bodyhaving an inlet, an outlet, and an actuation opening; a valve seatassembly disposed in the valve body between the inlet and the outlet; asleeve adjustably engageable with the valve body, the sleeve movablerelative to the valve body to be engaged and disengaged from the valveseat assembly; an actuation module engageable with the sleeve, theactuation module secured at the actuation opening with a lockingmechanism; a flow control disposable within the sleeve and configured toengage the valve seat assembly to close the flushometer system, the flowcontrol in communication and controlled by the actuation module; and thelocking mechanism engageable with a shoulder disposed adjacent theactuation opening, the locking mechanism at least partially capturedbetween the shoulder of the valve body and the actuation module when thesleeve is spaced apart from the valve seat assembly and the lockingmechanism being disengaged from the actuation module when the sleeve isengaged with the valve seat assembly.
 15. The flushometer system ofclaim 14, wherein the actuation module includes an automatic actuation.16. The flushometer system of claim 15, wherein the automatic actuationmodule includes a solenoid.
 17. The flushometer of claim 15, wherein theactuation module includes a piston assembly slidably disposed within thesleeve and affixed to the flow control at one end and positioned betweenthe flow control and the actuation module defining an upper chamberthere between, the piston assembly having a by-pass orifice providingfluid communication between the inlet and the upper chamber.
 18. Theflushometer system of claim 14, wherein the actuation module includes aactivation module passage there through and a relief valve stem slidablypositioned in the activation module passage with a lower stem capsealing a upper chamber from the outlet.
 19. The flushometer system ofclaim 18, wherein the relief valve stem having a flow portion that isslidably engageable with a vent opening in the activation module passagewherein the vent opening is in communication with the outlet.
 20. Theflushometer system of claim 14, wherein the sleeve is threadably engagedwith the valve body.